Andy_K 

I'm by no means an expert, but having removed a few Regina freewheels with that spline pattern recently I'll share what I did. There seems to be a disconnect in communication somewhere, so maybe repeating the procedure back and forth enough times will clarify what's going wrong.

I got the Park FR-4. It did not fit over the locknut on either a Campy hub or a Gipiemme hub, so I had to remove the locknut. As you say, the drive side lock nut is too deep in the freewheel, so I removed the NDS locknut and removed the axle, spilling bearings all over the place in the process. That could be difficult if the NDS cone is tight, but it worked for me just holding the axle while spinning off the cone. Once the locknut was out of the way, the FR-4 slipped right in to the splines.

Based on my reading of what you've said, it sounds like maybe the splines on your tool are a little bit too tall. There obviously isn't much room for play between a tool that will pass over the locknut but also fit into the splines on the freewheel. If the tool is meant for "Regina, Atom and Zeus" it may be that it's really built for Atom and Zeus and the splines are a bit too tall of (some?) Regina freewheels even though they're in the right place. Or maybe it's a manufacturing tolerance issue with your tool and/or freewheel. Obviously I'm stabbing in the dark here.

Kontact 

This is all spot on.

Looking at the VAR tool, it is either hitting the locknut or the splines aren't deep enough. The VAR spline valleys are not sharp Vs, and I'd bet that is the real issue. However, every Regina FW tool I've ever used or seen was very thin walled and fragile looking. That must have been for a good reason.

crandress 

Since I am new to the area, I only know about the current location. I have been wanting to get up there, so the swap meet may give me an opportunity depending on the hours. A day up to Madison without the wife in tow, have to take advantage, right??

crandress 

Thanks!! Looks like Cronometro is real close to the swap, so I may try that if I don't feel I have the time to get up to Yellow Jersey.

crandress 

This is a completely fair assessment and the more I have looked at it I agree. Whether manufacturing tolerances or whatever, it seems right, but not quite. And without the Park tool (since I bought the stupid VAR tool) taking off the locknut won't make a difference. (I swear this is not the problem as the VAR tool is deeper, really)

My original thought, and the initial question of the post, was that there were maybe two slightly different Regina splined freewheels. This does not appear to be the case. So, as I see it, there are two options left

1. buy the Park tool and take off the locknut to remove the axle and use the the tool,
2. take it to a shop and be done with it (hopefully!), or
3. figure I don't want to ride the tubulars anyway and forget the wheels! (but these are beautiful wheels! And yes, I have ridden tubulars before.)

I appreciate everyone's help on this!! And if anyone is at the Madison swap on Saturday, maybe I will see you there. Just look for the fat guy with the silly grin looking for vintage Campy stuff.

Kontact 

I used to work there - it is a small shop so there might be a wait on a Saturday. Closed Sunday. Great shop and the the best fitter in the Midwest.

El Chaba

If the axle is bent, that could be preventing the tool from inserting in the splines. I have seen that a few times.

miamijim

Wack real hard with a hammer

It’ll go in

crandress 

Rather than go to a shop, I purchased the Park tool instead. Not only did it fit perfectly, it fit WITHOUT the need to remove the axle locknut! And the freewheel came right off. No problem!! Wish I had started with the Park!!

Chombi1 

The park tool fit over the Campy locknut?? That's not supposed to happen,..... unless Park updated their tool to do so.
Good for you!

crandress 

It did indeed fit!!

crandress 

putting the two tool together, both have the correct number of splines that are all centered together. However, the splines on the VAR tool are just ever so slightly wider and taller. Glad I broke down and bought the Park tool!